EP3756866A1 - Matériau composite thermoplastique renforcé par des fibres, procédé de fabrication d'un matériau composite et utilisations correspondantes - Google Patents

Matériau composite thermoplastique renforcé par des fibres, procédé de fabrication d'un matériau composite et utilisations correspondantes Download PDF

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Publication number
EP3756866A1
EP3756866A1 EP19182557.9A EP19182557A EP3756866A1 EP 3756866 A1 EP3756866 A1 EP 3756866A1 EP 19182557 A EP19182557 A EP 19182557A EP 3756866 A1 EP3756866 A1 EP 3756866A1
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EP
European Patent Office
Prior art keywords
thermoplastic
layer
glass
composite material
mass
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
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Application number
EP19182557.9A
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German (de)
English (en)
Inventor
Norbert Förster
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Optiplan GmbH
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Optiplan GmbH
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Publication date
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Priority to EP19182557.9A priority Critical patent/EP3756866A1/fr
Publication of EP3756866A1 publication Critical patent/EP3756866A1/fr
Withdrawn legal-status Critical Current

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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/68—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts by incorporating or moulding on preformed parts, e.g. inserts or layers, e.g. foam blocks
    • B29C70/688—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts by incorporating or moulding on preformed parts, e.g. inserts or layers, e.g. foam blocks the inserts being meshes or lattices
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/06—Fibrous reinforcements only
    • B29C70/08—Fibrous reinforcements only comprising combinations of different forms of fibrous reinforcements incorporated in matrix material, forming one or more layers, and with or without non-reinforced layers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/06—Fibrous reinforcements only
    • B29C70/08—Fibrous reinforcements only comprising combinations of different forms of fibrous reinforcements incorporated in matrix material, forming one or more layers, and with or without non-reinforced layers
    • B29C70/081—Combinations of fibres of continuous or substantial length and short fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/06—Fibrous reinforcements only
    • B29C70/08—Fibrous reinforcements only comprising combinations of different forms of fibrous reinforcements incorporated in matrix material, forming one or more layers, and with or without non-reinforced layers
    • B29C70/083—Combinations of continuous fibres or fibrous profiled structures oriented in one direction and reinforcements forming a two dimensional structure, e.g. mats
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/06—Fibrous reinforcements only
    • B29C70/08—Fibrous reinforcements only comprising combinations of different forms of fibrous reinforcements incorporated in matrix material, forming one or more layers, and with or without non-reinforced layers
    • B29C70/086—Fibrous reinforcements only comprising combinations of different forms of fibrous reinforcements incorporated in matrix material, forming one or more layers, and with or without non-reinforced layers and with one or more layers of pure plastics material, e.g. foam layers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
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    • B29C70/10—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres
    • B29C70/12—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres using fibres of short length, e.g. in the form of a mat
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
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    • B29C70/10—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/06—Fibrous reinforcements only
    • B29C70/10—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres
    • B29C70/16—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres using fibres of substantial or continuous length
    • B29C70/20—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres using fibres of substantial or continuous length oriented in a single direction, e.g. roofing or other parallel fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/06—Fibrous reinforcements only
    • B29C70/10—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres
    • B29C70/16—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres using fibres of substantial or continuous length
    • B29C70/22—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres using fibres of substantial or continuous length oriented in at least two directions forming a two dimensional structure
    • B29C70/226—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres using fibres of substantial or continuous length oriented in at least two directions forming a two dimensional structure the structure comprising mainly parallel filaments interconnected by a small number of cross threads
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/28—Shaping operations therefor
    • B29C70/40—Shaping or impregnating by compression not applied
    • B29C70/50—Shaping or impregnating by compression not applied for producing articles of indefinite length, e.g. prepregs, sheet moulding compounds [SMC] or cross moulding compounds [XMC]
    • B29C70/504—Shaping or impregnating by compression not applied for producing articles of indefinite length, e.g. prepregs, sheet moulding compounds [SMC] or cross moulding compounds [XMC] using rollers or pressure bands
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/12—Layered products comprising a layer of synthetic resin next to a fibrous or filamentary layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/30—Layered products comprising a layer of synthetic resin comprising vinyl (co)polymers; comprising acrylic (co)polymers
    • B32B27/308—Layered products comprising a layer of synthetic resin comprising vinyl (co)polymers; comprising acrylic (co)polymers comprising acrylic (co)polymers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/32—Layered products comprising a layer of synthetic resin comprising polyolefins
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
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    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/36—Layered products comprising a layer of synthetic resin comprising polyesters
    • B32B27/365—Layered products comprising a layer of synthetic resin comprising polyesters comprising polycarbonates
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
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Definitions

  • the present invention relates to a fiber-reinforced, thermoplastic composite material according to claim 1, a method for producing a composite material according to claim 14 and the use according to claims 18 and 19.
  • thermoplastic composites consist of fiber-reinforced thermoplastic composites or contain them as cover layers are increasingly being used in leisure and commercial vehicles, in the field of electromobility, in the transport sector (e.g. transport containers) and in the construction, furniture and maritime industries.
  • thermoset flat webs or cover layers based on glass fiber-reinforced reactive resins are known from the prior art.
  • fiber-reinforced thermoplastic composite materials are produced by melt impregnation of different layers of glass fiber mats / layers with thermoplastic webs, mainly using the GMT process (glass mat reinforced thermoplastics) on double belt presses.
  • GMT process glass mat reinforced thermoplastics
  • glass rovings glass threads
  • UD tape technology UD tape technology
  • the disadvantage here is that the known methods regularly result in uneven, streaky and / or rough surfaces which, in particular, interfere with the formation of visible surfaces.
  • Different approaches to overcome this problem such as reworking the surface by filling, milling, polishing and painting, a fleece coating of the top and / or bottom of the semi-finished products produced, or the pressing of glass mats with the thermoplastic melt webs, were not sufficient to overcome the above-mentioned problem and could also be used for the mechanical properties of the composite materials, in particular the strength and rigidity of the Composite material, but also a low thermal expansion, be disadvantageous.
  • a fiber-reinforced, thermoplastic composite material having a first thermoplastic layer which contains or consists of a first, glass fiber-reinforced thermoplastic.
  • the first thermoplastic has glass fibers in a mass fraction between 5 and 60%, preferably between 20 and 40% (the sum of the mass of the polymer or polymers in the first thermoplastic and the mass of the glass fibers in the first thermoplastic being 100%) .
  • At least 60 mass%, preferably at least 80 mass%, of the glass fibers of the first, glass fiber-reinforced thermoplastic have a length of 8 to 10 mm.
  • the first thermoplastic has a melt flow index or the melt volume flow rate between 2 and 10 g / min, measured at 230 ° C. and 2.16 kg in accordance with DIN 53735 or ISO 1133.
  • the minor one Viscosity of the first thermoplastic leads to good melt impregnation and brings optimal consolidation results in the composite material according to the invention.
  • the specified range of the melt flow index allows good processability and adequate dispersibility of the glass fibers.
  • a melt flow index of more than 10 g / min processing difficulties arise due to the low viscosity during the smoothing step (e.g. the thermoplastic melt flows out of a calender or the like during processing).
  • melt flow index is less than 2 g / min, the mutual penetration of glass fibers and thermoplastic deteriorates. If the melt flow index of the first thermoplastic has a value outside the range according to the invention between 2 and 10 g / min, processing problems, in particular insufficient adhesion and even delamination of individual or multiple layers, can also occur if a lamination step is provided.
  • the invention focuses on the provision of thermoplastics as polymers for the matrix, while according to the invention thermosets are not provided as polymers for the matrix.
  • the composite material according to the invention is preferably produced by a method which comprises at least the following steps: (a) extruding the first thermoplastic, preferably by means of a slot die, whereby the first thermoplastic layer is obtained; and (b) smoothing the first thermoplastic layer, preferably by means of a smoothing device.
  • the inventors of the present invention have recognized that the mechanical properties of the desired composite materials can only be ensured if the fiber material and the polymer matrix interact appropriately.
  • the composite material according to the invention it is ensured that the fibers or fiber bundles embedded in the matrix overlap or overlap or overlap, that is to say touch one another.
  • An example of the fiber structure of a fiber composite material according to the invention is shown in Fig. 1 shown schematically. This shows that most of the fibers are long enough to touch another fiber in one or two places. In the figure are the points of intersection (places of intersection or superposition or overlap) marked by circles. Such an overlap requires, on the one hand, a sufficient fiber length. On the other hand, a sufficiently uniform distribution or dispersion of the fibers within the polymer matrix is necessary.
  • the embedding of the fibers in the polymer functioning as a matrix has the effect that the fibers or fiber bundles are permanently connected to one another or touch one another.
  • the connection or contact of the fibers with one another enables the fibers to transfer the force when a force is applied (tension, bending, dynamics).
  • FIG Fig. 2 An example of a fiber structure with short glass fibers or glass fiber bundles which do not correspond to the fiber composite material according to the invention is shown in FIG Fig. 2 shown schematically. As in Fig. 2 recognizable, this structure lacks an overlap or superposition of the fibers or fiber bundles.
  • the advantage of the overlap is achieved through the use of a polymer which has been reinforced with long glass fibers or long fibers (long glass fiber reinforced polymer).
  • long glass fiber reinforced polymer so-called chopped strand mats or cut mats can be used for fiber reinforcement (cf. Fig. 3 ).
  • At least 60% by mass, preferably at least 80% by mass, of the glass fibers in the finished composite material have a length of 8 to 10 mm. If the fiber length were considerably shorter, this would have the disadvantage that the overlapping or superposition of the fibers or fiber bundles is less and the force transmission is correspondingly reduced. This would impair the mechanical properties. Conversely, the overlapping or superposition of the glass fibers is better the longer the fibers are.
  • the length of the glass fibers of 8 to 10 mm provided according to the invention also has the advantage that a good dispersion of the phases in the polymer matrix can still be achieved with glass fibers of this length. Fibers that are longer than 10 mm make it difficult to produce a homogeneous distribution or uniform dispersion of the fibers in the polymer matrix.
  • the composite material according to the invention is produced by extruding a first thermoplastic, whereby a first thermoplastic layer is obtained, which can then be smoothed, preferably by means of a smoothing device.
  • a fiberglass-reinforced thermoplastic is used for flat sheet extrusion.
  • glass fiber reinforced thermoplastics are at best used in injection molding to manufacture parts.
  • the smoothing tools have a temperature between 30 and 110 ° C. This achieves an optimal penetration depth of the glass fiber bundles into the polymer matrix.
  • FIG. 5 shows an example of a section from a fiber matrix of a composite material according to the invention: in it the polymer was annealed in a muffle furnace to make the pure fiber matrix visible.
  • the homogeneous distribution and uniform alignment of the fibers in space or in the area can be seen particularly well.
  • a large number of points of intersection or overlap of the individual fiber bundles can be seen.
  • the inventors assume that when using a smoothing mechanism, for example, intensive mixing or “confusion” of the fiber bundles in the still plastic polymer matrix, which is present as a rolling bead, takes place. In this way, a spatial uniform distribution of the fiber orientation is achieved, whereby the strength of the resulting composite material is advantageously improved.
  • the smoothing has the effect of "smoothing out" the surface of the fiber-reinforced polymer matrix. This ultimately results in a comparatively smooth first thermoplastic layer in which the fiber bundles are arranged quasi randomly and confusedly with regard to their spatial alignment.
  • the glass fibers on the first thermoplastic have a mass fraction between 5 and 60%, preferably between 20 and 40%, in particular between 30 and 40%. If the mass fraction of the glass fibers is less than 20%, in particular less than 5%, the probability of an overlap / overlay / overlap of the glass fiber bundles is too low to ensure the desired mechanical properties. If, on the other hand, the mass fraction of the glass fibers is more than 40%, in particular more than 60%, the effect of the polymer matrix as a connecting carrier element may no longer be ensured.
  • the mass fraction of the glass fibers in the thermoplastic must not exceed 60%, preferably 40%.
  • the mass fraction of the glass fibers in the thermoplastic must not exceed 60%, preferably 40%.
  • an adequate connection between the polymer matrix and the glass fibers can no longer be ensured, so that the impregnation of the glass fibers with the polymer matrix is no longer sufficient. This in turn leads to a deterioration in the mechanical properties.
  • the glass fibers are gently conveyed during the production of the composite material according to the invention. This can be achieved, for example, by using suitable extrusion screws.
  • this technique it is possible to create the long glass fiber structure with an initial length of 8 to 10 mm to be largely or predominantly obtained during processing.
  • at least 60% by mass, preferably at least 80% by mass, of the glass fibers of the first thermoplastic have a length of 8 to 10 mm. Because a large proportion of the glass fibers have a length in the specified range, which are also known as long fibers, a high mechanical stability is achieved.
  • the object according to the invention is also achieved by the fiber-reinforced, thermoplastic composite material according to claim 2.
  • a fiber-reinforced, thermoplastic composite material which has a glass lattice fabric layer which contains or consists of a glass lattice fabric.
  • the composite material also has a first thermoplastic layer which contains or consists of a first glass fiber-reinforced thermoplastic.
  • the first thermoplastic has glass fibers in a mass fraction between 5 and 60%, preferably between 20 and 40%. At least 60% by mass, preferably at least 80% by mass, of the glass fibers of the first thermoplastic have a length of 8 to 10 mm.
  • the first thermoplastic has a melt flow index between 2 and 10 g / min, measured at 230 ° C. and 2.16 kg in accordance with DIN 53735.
  • the composite material according to the invention according to the second aspect not only has the features and advantages mentioned in connection with the first aspect described above.
  • the composite material according to the second aspect also has a glass lattice fabric, which brings about an even more uniform or more homogeneous distribution of the long glass fibers in the adjacent thermoplastic layer or the adjacent thermoplastic layers. This further improves the mechanical strength.
  • the resulting composite material is characterized by particularly low thermal expansion. This makes it possible to successfully prevent the resulting thermoplastic layer or the resulting composite material from dishing during production by means of flat film extrusion and thereafter, in particular in its or its edge region. In addition, the low thermal expansion also improves the cold stability of the composite material.
  • the flexural strength and rigidity of the composite material according to the invention can also be further improved. Furthermore, partial or complete delamination of the composite material is successfully avoided by providing the glass mesh. Finally, the use of the glass lattice structure stabilizes the manufacturing process and compensates for or reduces the manufacturing tolerances.
  • the glass mesh can vary in terms of the thread thickness in the warp and weft.
  • the object according to the invention is also achieved by the fiber-reinforced, thermoplastic composite material according to claim 3.
  • a fiber-reinforced, thermoplastic composite material which has a glass lattice layer which contains or consists of a glass mesh fabric.
  • the composite material also has a first thermoplastic layer which contains or consists of a first glass fiber-reinforced thermoplastic.
  • the composite material furthermore has a second thermoplastic layer which contains or consists of a second glass fiber reinforced thermoplastic.
  • the first thermoplastic has glass fibers in a mass fraction between 5 and 60%, preferably between 20 and 40%. At least 60% by mass, preferably at least 80% by mass, of the glass fibers of the first thermoplastic have a length of 8 to 10 mm.
  • the first thermoplastic has a melt flow index between 2 and 10 g / min, measured at 230 ° C. and 2.16 kg in accordance with DIN 53735.
  • the second thermoplastic has glass fibers in a mass fraction between 5 and 60%, preferably between 20 and 40%. At least 60% by mass, preferably at least 80% by mass, of the glass fibers of the second thermoplastic have a length of 8 to 10 mm.
  • the second thermoplastic has a melt flow index between 2 and 10 g / min, measured at 230 ° C. and 2.16 kg in accordance with DIN 53735.
  • the composite material according to the invention according to the third aspect not only has the features and advantages mentioned in connection with the first and second aspects described above.
  • the composite material according to the third aspect furthermore has a second thermoplastic layer with a second thermoplastic which has a melt flow index between 2 and 10 g / min.
  • the second thermoplastic layer allows a particularly uniform application of an external decorative layer, i.e. a decorative layer with a constant thickness and surface flatness.
  • the second thermoplastic layer is applied to the side of the glass lattice layer opposite the first thermoplastic layer, the embedding of the glass lattice layer is further improved with the resulting sandwich structure. This further improves the mechanical properties of the resulting composite material.
  • the bowl can be further reduced.
  • the tendency to delaminate the entire structure is further reduced.
  • the scrim can be laminated on one or both sides with a glass fleece, with one-sided lamination usually being sufficient.
  • a glass fleece increases the dimensional and shape stability, reduces possible warpage, tension, expansion and shrinkage. It also counteracts the effect of any uneven tensile forces that may be applied during manufacture.
  • the glass fleece can prevent the thermoplastic layer from penetrating into the glass lattice fabric and the polymer from "penetrating” or "dripping through” the calender and thus supports spatial fixing of the thermoplastic layers. To prevent the polymer from breaking through One-sided lamination with a glass fleece on the calender is usually sufficient.
  • the provision of a glass lattice structure prevents a tensile force acting on the composite material from acting completely on the polymer matrix. Rather, the tensile force is at least partially absorbed by the glass mesh. As a result, the tensile strength of the composite material and thus its dimensional stability can be further improved.
  • the first thermoplastic can contain at least one polymer or consist of one polymer or consist of a mixture of several polymers.
  • the polymer is selected from a group consisting of: a polyolefin, in particular polyethylene or polypropylene, a polyamide, a thermoplastic olefin, a thermoplastic elastomer, a polycarbonate, a polyacrylic, a copolymer of the same, a thermoplastic blend, and a reactive one Polymer, preferably an unsaturated polyester resin, an epoxy resin or a polyurethane.
  • polypropylene is preferably used for the first thermoplastic, since it has very good usage and processing properties, such as good adhesion properties to the substrate / other components, is readily available and inexpensive, has a favorable ecological balance, is odorless, emission-free and recyclable and has a comparatively low mass or density.
  • the composite material according to the invention with polypropylene as the first thermoplastic can be thermally welded to other polypropylene-containing components without the need for gluing.
  • the second thermoplastic can contain at least one polymer or consist of one polymer or consist of a mixture of several polymers, wherein the polymer is selected from a group consisting of: a polyolefin, in particular polyethylene or polypropylene, a polyamide, a thermoplastic olefin, a thermoplastic elastomer, a polycarbonate, a polyacrylic, a copolymer of the same, a thermoplastic blend, and a reactive Polymer, preferably an unsaturated polyester resin, an epoxy resin or a polyurethane.
  • polypropylene is preferably used for the second thermoplastic, for the same reasons as explained above for the first thermoplastic.
  • the first thermoplastic layer can have been connected to the glass lattice fabric by means of extrusion. Thanks to the extrusion technology, an intimate penetration of thermoplastic and glass fibers is achieved. In addition, the lengths of the glass fibers are largely retained during the extrusion of the glass fiber-thermoplastic mixture or only decrease slightly, in particular if gentle plasticizing screws are also used during the extrusion.
  • the composite material can have a glass content of 15 to 35 percent by mass, preferably 20 to 30 percent by mass, in particular 23 to 27 percent by mass.
  • the inventors have found that composite materials which have a proportion of glass deviating from the specified ranges, in particular a higher proportion of glass, lead to uneven or uneven surfaces of the resulting composite material. In addition, such composite materials cannot be produced economically. If the proportion of glass is too low, as shown above, the crosslinking or contact of the individual glass fibers or glass fiber bundles is reduced, as a result of which the mechanical properties described deteriorate.
  • the glass lattice fabric can have a glass and a third thermoplastic.
  • the proportion of glass in the glass lattice structure can preferably be 50 to 70 percent by mass, in particular 55 to 65 percent by mass.
  • the proportion of the third thermoplastic in the glass lattice structure can preferably be 30 to 50 percent by mass, in particular 35 to 45 percent by mass.
  • the third thermoplastic can contain at least one polymer or consist of a polymer or consist of a mixture of several polymers, the polymer being selected from a group consisting of: a polyolefin, in particular polyethylene or polypropylene, a polyamide, a thermoplastic olefin, a thermoplastic elastomer, a polycarbonate, a polyacrylic, a copolymer thereof, a thermoplastic blend, and a reactive polymer, preferably an unsaturated polyester resin, an epoxy resin or a polyurethane.
  • the third thermoplastic is preferably a polyolefin, in particular polypropylene.
  • the glass lattice fabric can also preferably have polyester, natural materials, aramid, carbon, basalt, carbon, higher-melting polymers and / or hybrid fibers.
  • the glass lattice fabric can preferably be impregnated or sheathed with an adhesion promoter.
  • the provision of the third thermoplastic in the glass lattice fabric further improves the uniformity or homogeneity of the distribution of the long glass fibers in the adjacent thermoplastic layer or the adjacent thermoplastic layers.
  • the third thermoplastic facilitates the connection or anchoring of the adjacent thermoplastic layer (s) to the glass mesh layer or layers.
  • the glass lattice fabric can have a lattice structure, preferably a square lattice structure.
  • the edge lengths of the squares can be 1 to 6 mm, preferably 2 to 4 mm, in particular 2.5 to 3.5 mm.
  • edge length of the squares is too large, for example greater than 6 mm, the bonding effect between the glass mesh and the polymer matrix is not sufficient. If, on the other hand, the edge length of the squares is too small, for example less than 2 mm, the polymer does not penetrate sufficiently into the glass lattice fabric or through the glass lattice fabric so that the bond between the glass lattice fabric and the polymer matrix is insufficient. An edge length of 3 ( ⁇ 0.2) mm is particularly preferred.
  • the yarn making up the glass mesh can be impregnated, but does not have to be.
  • a suitable impregnation can, however, be advantageous in order to ensure an optimal connection between the glass mesh fabric and the polymer matrix or thermoplastic material.
  • the yarn of the glass mesh must not fall below a predetermined diameter in order to ensure a sufficient contribution of the glass mesh to mechanical stability.
  • the yarn of the glass lattice fabric must not exceed a predetermined diameter, since otherwise the penetration or penetration of the polymer matrix through the glass lattice fabric would be prevented.
  • the composite material can have a PET fleece layer.
  • the PET fleece layer can consist of a PET fleece which contains or consists of polyethylene terephthalate.
  • the PET fleece preferably has a weight per unit area of 20 to 60 g / m 2 , preferably from 30 to 50 g / m 2 .
  • the PET nonwoven layer has the advantage that penetration or dripping through the polymer matrix and sticking of the polymer matrix to a roller of the smoothing tool is avoided.
  • the PET nonwoven can bond the composite material according to the invention to an underlying, i.e. On the inside of the composite material according to the invention, improve the core structure, such as a foam or honeycomb structure, and represents the bond side. It is particularly advantageous if the connection is based on mechanical adhesion without bonding or any other type of chemical bonding would be required.
  • the composite material can have a decorative layer, the decorative layer preferably being extruded using the inline coating process.
  • the decorative layer can consist of a decorative material which contains or consists of a fourth thermoplastic.
  • the fourth thermoplastic can contain at least one polymer or consist of a polymer or consist of a mixture of several polymers, the polymer being selected from a group consisting of: a polyolefin, in particular polyethylene or polypropylene, a polyamide, a thermoplastic olefin, a thermoplastic elastomer, a polycarbonate, a polyacrylic, a copolymer thereof, a thermoplastic blend, and a reactive polymer, preferably an unsaturated polyester resin, an epoxy resin or a polyurethane.
  • the fourth thermoplastic is preferably a polyolefin, in particular polypropylene.
  • the decorative layer preferably does not contain any glass fibers.
  • the decorative layer can in particular be provided and used to design the external appearance of the composite material.
  • the first thermoplastic layer contains or consists of the first thermoplastic.
  • the first thermoplastic has glass fibers in a mass fraction between 5 and 60%, preferably between 20 and 40%. At least 60 mass%, preferably at least 80 mass%, of the glass fibers of the first thermoplastic have a length of 8 to 10 mm.
  • the first thermoplastic has a melt flow index between 2 and 10 g / min, measured at 230 ° C. and 2.16 kg in accordance with DIN 53735.
  • the temperature of the first thermoplastic is preferably set to a temperature between 220 and 230 ° C. during the extrusion in step (a).
  • the first thermoplastic layer contains or consists of the first thermoplastic.
  • the first thermoplastic has glass fibers in a mass fraction between 5 and 60%, preferably between 20 and 40%. At least 60 mass%, preferably at least 80 mass%, of the glass fibers of the first thermoplastic have a length of 8 to 10 mm.
  • the first thermoplastic has a melt flow index between 2 and 10 g / min, measured at 230 ° C. and 2.16 kg in accordance with DIN 53735.
  • the temperature of the first thermoplastic is preferably set to a temperature between 220 and 230 ° C. during the extrusion in step (a).
  • the glass mesh layer contains or consists of a glass mesh.
  • the second thermoplastic layer can contain or consist of the second thermoplastic.
  • the second thermoplastic can have glass fibers in a mass fraction between 5 and 60%, preferably between 20 and 40%. At least 60 mass%, preferably at least 80 mass%, of the glass fibers of the second thermoplastic can have a length of 8 to 10 mm.
  • the second thermoplastic can have a melt flow index between 2 and 10 g / min, measured at 230 ° C. and 2.16 kg in accordance with DIN 53735.
  • the decorative layer can be extruded using the inline coating process.
  • the decorative layer can consist of a decorative material which contains or consists of a fourth thermoplastic.
  • the fourth thermoplastic can be a polyolefin, in particular polypropylene.
  • the decorative layer preferably does not contain any glass fibers.
  • the use of a glass fiber reinforced thermoplastic as a material for a composite material is claimed to improve the mechanical properties, preferably the strength, the rigidity and the low thermal expansion, of the composite material.
  • the glass fiber reinforced thermoplastic has glass fibers in a mass fraction between 5 and 60%, preferably between 20 and 40%. At least 60 mass%, preferably at least 80 mass%, of the glass fibers of the glass fiber reinforced thermoplastic have a length of 8 to 10 mm.
  • the glass fiber reinforced thermoplastic has a thermoplastic polymer with a melt flow index between 2 and 10 g / min, measured at 230 ° C. and 2.16 kg according to DIN 53735.
  • the use of a glass lattice fabric for the production of a composite material is claimed, the glass lattice fabric being extruded with a melt web of a thermoplastic in order to increase the dimensional and tensile strength and / or the stability of the composite material in terms of mechanical stability (flexural strength, rigidity and / or avoidance of Bowls) and / or to improve the temperature stability (heat and / or cold stability).
  • the composite material is preferably treated by means of a smoothing mechanism.
  • the invention is not necessarily restricted to the layer structures shown below, but can include further layer structures.
  • the composite material according to the invention can each have further additional layers, in particular one or more intermediate layers between individual or several adjacent pairs of layers specified in the examples.
  • the composite material of example 1 can be produced, for example, by extruding the first thermoplastic using a slot die and smoothing the first thermoplastic layer using a smoothing device.
  • a specific embodiment of example 1 is a composite material having a layer (BS) containing or consisting of a polypropylene (long glass fiber reinforced) with 30% long glass fibers (GF), density 1120 kg / m 3 (ISO 1183), melt flow index: 2 g / 10 min (230 ° C., 2.16 kg, ISO 1133), at least 60% by mass of the glass fibers have a length of 8 to 10 mm; Layer thickness: 0.4 mm (cf. exemplary, not to scale and schematic sectional view of the composite material according to Example 1 in Fig. 6 ).
  • BS layer containing or consisting of a polypropylene (long glass fiber reinforced) with 30% long glass fibers (GF), density 1120 kg / m 3 (ISO 1183), melt flow index: 2 g / 10 min (230 ° C., 2.16 kg, ISO 1133), at least 60% by mass of the glass fibers have a length of 8 to 10 mm; Layer thickness: 0.4 mm (cf. exemplary, not to
  • the glass lattice layer contains or consists of a glass lattice, the glass lattice having a square lattice structure with an edge length of the squares of 3 mm, for example.
  • the glass mesh fabric can preferably consist of 60% by mass of glass and 40% by mass of polypropylene.
  • the glass lattice fabric can have a glass fleece on one or both sides, preferably on one side.
  • the composite material of Example 2 can be produced, for example, by extruding the first thermoplastic using a slot die, applying the first thermoplastic layer obtained in this way to the glass mesh layer and smoothing the resulting composite using a smoothing device.
  • the glass lattice layer contains or consists of a glass lattice, the glass lattice having a square lattice structure with an edge length of the squares of 3 mm, for example.
  • the glass mesh fabric can preferably consist of 60% by mass of glass and 40% by mass of polypropylene.
  • the glass lattice fabric can have a glass fleece on one or both sides, preferably on one side.
  • the composite material of Example 3 can be produced, for example, by extruding the first thermoplastic by means of a slot die, applying the first thermoplastic layer obtained thereby to the glass mesh layer and smoothing the resulting composite by means of a smoothing device, extruding the second thermoplastic by means of a slot die, applying the The second thermoplastic layer obtained in the process is applied to the side of the glass lattice fabric layer of the composite obtained above, which is opposite the first thermoplastic layer, and the resulting composite is smoothed by means of a smoothing device.
  • thermoplastic composite material with a first thermoplastic layer, a glass mesh layer, a second thermoplastic layer and a decorative layer (in this layer sequence).
  • the glass lattice layer contains or consists of a glass lattice, the glass lattice having a square lattice structure with an edge length of the squares of 3 mm, for example.
  • the glass mesh fabric can preferably consist of 60% by mass of glass and 40% by mass of polypropylene.
  • the glass lattice fabric can have a glass fleece on one or both sides, preferably on one side.
  • the decorative layer consists of a decorative material which contains or consists of a fourth thermoplastic.
  • the fourth thermoplastic is preferably a polyolefin, in particular natural polypropylene, density 900 to 1000 kg / m 3 (ISO 1183), melt flow index: 6.5 g / 10 min (230 ° C., 2.16 kg, ISO 1133), masterbatch Colour.
  • the composite material of example 4 can be produced, for example, by extruding the first thermoplastic by means of a slot die and applying it the first thermoplastic layer obtained in this way onto the glass lattice layer and smoothing of the resulting composite by means of a smoothing device, extrusion of the second thermoplastic by means of a slot die, application of the second thermoplastic layer obtained thereby to the side of the glass lattice fabric layer of the above-obtained composite opposite the first thermoplastic layer and smoothing the resulting composite by means of a smoothing device, extruding the decorative layer, preferably using the inline coating process, laminating the decorative layer onto the second thermoplastic layer of the previously obtained composite and smoothing the resulting composite by means of a smoothing device.
  • Examples 1a (AS / BS), 2a (AS / BS / CS), 3a (AS / BS / CS / DS), 4a (AS / BS / CS / DS / ES):
  • Examples 1a, 2a, 3a, and 4a are disclosed, which are each identical to the aforementioned Examples 1, 2, 3 and 4, with the exception that the composite materials of Examples 1a, 2a, 3a, and 4a each additionally still have a PET fleece layer.
  • the PET fleece layer consists of a PET fleece which contains or consists of polyethylene terephthalate.
  • the PET fleece has. preferably a basis weight of 20 to 60 g / m 2 .
  • the PET nonwoven layer is in each case arranged as the innermost layer, adjacent to the first thermoplastic layer.
  • the composite material of Examples 1a, 2a, 3a, and 4a can be produced, for example, as described above for Examples 1, 2, 3 and 4, although the first step is an extrusion of the first thermoplastic using a slot die onto a PET - non-woven layer (bonding side) can include (see. Example 1a). If the composite material also contains a glass mesh layer (cf. Examples 2a, 3a, and 4a), the first step preferably comprises extruding the first thermoplastic by means of a slot nozzle between the PET fleece layer and the glass mesh layer.
  • the composite material of Example 1a can be produced, for example, by extruding the first thermoplastic by means of a slot die onto a PET nonwoven layer (bond side) and smoothing the first thermoplastic layer by means of a smoothing device.
  • Examples 1a, 2a, 3a, and 4a are identical to the specific embodiments as disclosed above for Examples 1, 2, 3 and 4, with the exception that the composite materials of Examples 1a, 2a, 3a, and 4a each have an additional layer further inside the respective first layer , preferably have PET nonwoven layer (AS) arranged adjacent to the respective first layer, having or consisting of PET nonwoven (bond side), 50 g / m 2 , layer thickness: 0.2 mm.
  • AS PET nonwoven layer
  • thermoplastic composite material with a PET fleece layer, a first thermoplastic layer, a glass mesh layer and a second thermoplastic layer (in this layer sequence).
  • the PET fleece layer consists of a PET fleece which contains or consists of polyethylene terephthalate.
  • the PET fleece preferably has a weight per unit area of 20 to 60 g / m 2 .
  • the glass lattice layer contains or consists of a glass lattice, the glass lattice having a square lattice structure with an edge length of the squares of 3 mm, for example.
  • the glass mesh fabric can preferably consist of 60% by mass of glass and 40% by mass of polypropylene.
  • the glass lattice fabric can have a glass fleece on one or both sides, preferably on one side.
  • the composite material of Example 5 can be produced, for example, by extruding the first thermoplastic by means of a slot die between the PET fleece layer and the glass mesh layer and smoothing the resulting composite by means of a smoothing device, extruding the second thermoplastic by means of a slot nozzle, applying the second obtained Thermoplastic layer on the opposite side of the glass lattice fabric layer of the composite obtained above from the first thermoplastic layer, and smoothing of the composite obtained thereby by means of a smoothing device.
  • thermoplastic composite material with a PET fleece layer, a first thermoplastic layer, a glass mesh layer, a second thermoplastic layer and a decorative layer (in this layer sequence).
  • the PET fleece layer consists of a PET fleece which contains or consists of polyethylene terephthalate.
  • the PET fleece preferably has a weight per unit area of 20 to 60 g / m 2 .
  • the glass lattice layer contains or consists of a glass lattice, the glass lattice having a square lattice structure with an edge length of the squares of 3 mm, for example.
  • the glass mesh fabric can preferably consist of 60% by mass of glass and 40% by mass of polypropylene.
  • the glass lattice fabric can have a glass fleece on one or both sides, preferably on one side.
  • the decorative layer consists of a decorative material which contains or consists of a fourth thermoplastic.
  • the fourth thermoplastic is preferably a polyolefin, in particular natural polypropylene, density 900 to 1000 kg / m 3 (ISO 1183), melt flow index: 6.5 g / 10 min (230 ° C., 2.16 kg, ISO 1133), masterbatch Colour.
  • the composite material of Example 6 can be produced, for example, by extruding the first thermoplastic using a slot die between the PET fleece layer and the glass mesh layer and smoothing the resulting composite using a smoothing device, extruding the second thermoplastic using a slot die, and applying the second obtained Thermoplastic layer on the opposite side of the glass mesh layer of the composite obtained above from the first thermoplastic layer, smoothing of the composite obtained in this way by means of a smoothing device, and extrusion of the decorative layer, preferably in the inline coating process, lamination of the decorative layer on the second thermoplastic layer of the previously obtained composite and smoothing the resulting composite by means of a smoothing device.
  • the claimed process according to the invention can be carried out with the systems known to those skilled in the art for producing technical films in the field of the invention.
  • the composite materials claimed according to the invention can also be produced with these systems.

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  • Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Composite Materials (AREA)
  • Mechanical Engineering (AREA)
  • Textile Engineering (AREA)
  • Laminated Bodies (AREA)
EP19182557.9A 2019-06-26 2019-06-26 Matériau composite thermoplastique renforcé par des fibres, procédé de fabrication d'un matériau composite et utilisations correspondantes Withdrawn EP3756866A1 (fr)

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Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
IT202100028346A1 (it) * 2021-11-08 2023-05-08 Renolit Gor Spa Lastra in materiale composito, multistrato ad elevata deformabilità tridimensionale

Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP0643091A1 (fr) * 1993-09-11 1995-03-15 BASF Aktiengesellschaft Produit semi-fini en feuille
EP0758577A1 (fr) * 1995-03-01 1997-02-19 Kawasaki Steel Corporation Feuille a estamper fabriquee selon les techniques de papeterie, et procede de fabrication d'une feuille a estamper moulee et legere
EP1369223A1 (fr) * 2001-02-15 2003-12-10 JFE Steel Corporation Materiau de resine lamine
EP2466030A1 (fr) * 2010-12-17 2012-06-20 Sika Technology AG Utilisation de feuilles d'étanchéité en polyoléfine revêtues de matière collante thermofusible non réactive et destinées à l'étanchéification

Patent Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP0643091A1 (fr) * 1993-09-11 1995-03-15 BASF Aktiengesellschaft Produit semi-fini en feuille
EP0758577A1 (fr) * 1995-03-01 1997-02-19 Kawasaki Steel Corporation Feuille a estamper fabriquee selon les techniques de papeterie, et procede de fabrication d'une feuille a estamper moulee et legere
EP1369223A1 (fr) * 2001-02-15 2003-12-10 JFE Steel Corporation Materiau de resine lamine
EP2466030A1 (fr) * 2010-12-17 2012-06-20 Sika Technology AG Utilisation de feuilles d'étanchéité en polyoléfine revêtues de matière collante thermofusible non réactive et destinées à l'étanchéification

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
IT202100028346A1 (it) * 2021-11-08 2023-05-08 Renolit Gor Spa Lastra in materiale composito, multistrato ad elevata deformabilità tridimensionale
WO2023079533A1 (fr) * 2021-11-08 2023-05-11 Renolit Gor S.P.A. Plaque en matériau composite multicouches à déformabilité tridimensionnelle élevée

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